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We come to the conclusion that it's a manufacturing issue, perhaps aided by a "less than optimal" layout. Since we now have a work-around, we're going to cross our fingers and hope the next design works better.
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Is the 'next design' a completely difference design, or the same design with a cleaner PCB layout? Regardless, I would recommend you plan on creating a small run of prototype/pre-roduction boards, and confirm the issue has been resolved. I typically find that 5 boards is a good minimum number of boards, as it allows you to discard one or two boards with assembly related issues, and focus on the real problems.
Cheers,
Dave
Honored Contributor
